Bracket system

ABSTRACT

Packaging for axle assemblies having a pair of wheel end assemblies. Each wheel end assembly includes studs. A base bracket has a main body portion with a receiving surface to support a portion of a first axle assembly. A slot extends from the receiving surface to accept a stud. At least one end portion extends from the main body portion. An intermediate bracket includes a first receiving surface at a first end of the intermediate bracket. The first receiving surface engages a portion of the first axle assembly. A slot extends from the first receiving surface to accept a stud of the first axle assembly. A second receiving surface is located at a second end of the intermediate bracket. The second receiving surface supports a portion of a second axle assembly. A slot extends from the second receiving surface to accept a stud of the second axle assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/372,420 filed Aug. 9, 2016.

TECHNICAL FIELD

This application generally relates to structure for arranging, packaging and shipping axle assemblies that are used in heavy-duty vehicles. Particularly, this application relates to a bracket configuration and method for arranging, packaging and shipping multiple axle assemblies in a stacked and spaced relationship.

BACKGROUND

It is known to ship vehicle parts, such as heavy-duty vehicle axle assemblies from an axle assembly fabrication plant to a heavy-duty vehicle assembly plant by truck or tractor and trailer. One such heavy-duty vehicle axle assembly is of the non-integrated axle type. That is, the axle assembly does not necessarily include suspension components. The axle assembly typically includes wheel end assemblies with or without brake systems. The axle assemblies are typically large, heavy and difficult to handle and package for shipping. The axle assemblies are subject to damage if they contact one another during packaging and/or transport or if they contact other structure associated with shipping.

The cost of shipping over-the-road, usually by tractor and trailer, is affected by the number of axle assemblies that can be shipped on a typical trailer. Typically, the axle assemblies were shipped in a package of two using a first wood pallet, wood blocks and steel strapping that are relatively expensive and discarded to cause an unrecoverable cost of shipping.

It is possible to stack a second wood pallet on the first wood pallet package. This requires even more wood blocks to space and support the second wood pallet relative to the first wood pallet since the second wood pallet would not be stable if resting on axle assemblies on the first pallet. Even more steel strapping secures the pallets together. The wood pallets, wood blocks and steel strapping are typically discarded after a single shipment. This known packaging and shipping method generally allows a maximum of twenty-six axle assemblies to be shipped in a single trailer load.

Thus, it would be desirable to provide a way to ship more axle assemblies in a single trailer load; eliminate the use of shipping materials that are discarded; be able to recover and reuse structures that support, arrange, package and ship the axle assemblies in a manner that prevents or minimizes the possibility of damage by contact with other axle assemblies or other structure; and provide a structure that is relatively easy to manufacture.

SUMMARY

A summary is provided to introduce concepts in a form that are described below. This summary is not intended to identify key factors or essential features of the subject matter of this application, nor is it intended to be used to limit the scope of the subject matter or the appended claims.

One aspect of this application is a system for packaging axle assemblies in a stacked and spaced arrangement. Each axle assembly has a pair of wheel end assemblies and a pair of brake assemblies mounted at opposite ends of an axle. Each wheel end assembly includes a hub with studs extending from the hub.

The system includes a base bracket with a main body portion. The main body portion has a receiving surface to engage and support a portion of a first axle assembly, such as a lower portion of the first axle assembly. The main body portion has at least one slot extending from the receiving surface to accept one of the studs. The main body portion also has at least one end portion extending transversely from the main body portion to stand the base bracket upright and stabilize the base bracket on a support surface. The end portion extends a distance at least equal to a distance that the hub and studs extend from the main body portion to protect the hub and studs from damage by contact with truck/trailer structure, other structure when being moved or material handling equipment.

The system also includes an intermediate bracket with a first receiving surface located at a lower or first end of the intermediate bracket. The first receiving surface of the intermediate bracket receives and engages another portion of the first axle assembly, such as an upper portion of the first axle assembly. At least one slot extends from the first receiving surface of the intermediate bracket to accept another stud of the first axle assembly. A second receiving surface is located at an upper or opposite second end of the intermediate bracket. The second receiving surface engages and supports a portion of a second axle assembly, such as a lower portion of the second axle assembly, in a position above the first axle assembly. At least one slot extends from the second receiving surface to accept a stud of the second axle assembly.

Two end portions extend in the same direction transversely from the main body portion. At least one of the end portions extends a distance at least equal to a distance that the hub and studs extend from the main body portion. Another receiving surface on the base bracket receives a portion of another axle assembly. Another receiving surface on the intermediate bracket receives a portion of the other axle assembly.

Another base bracket receives and supports a second end portion of the first axle assembly. Another intermediate bracket receives and secures a second end portion of the first axle assembly. The receiving surface has at least one arcuate surface. Structure is provided for at least one brake assembly to engage and inhibit rotation of the brake assembly.

A cover material is on at least one of the receiving surface and slot of at least one of the base bracket and intermediate bracket to protect components of the axle assembly. More than one stud slot extends from the receiving surface of at least one of the base bracket and intermediate bracket. A fastener is threaded onto the stud to clamp and secure an axle assembly to a bracket and inhibit relative movement in all directions between the bracket and the wheel end assembly.

Another aspect of this application is a method of packaging axle assemblies in a stacked and spaced arrangement. The method includes providing a base bracket according to the structure described above. A first axle assembly is placed in the base bracket so a portion of the first axle engages a receiving surface of the main body portion and a stud is received in a slot.

The method also includes providing an intermediate bracket according to the structure described above. The intermediate bracket is placed on the first axle assembly so a portion of a first axle engages a downward facing receiving surface of the intermediate bracket and another stud of the first axle assembly is received in a slot extending from the downward facing receiving surface. Then a second axle assembly is placed on the intermediate bracket so a portion of the second axle engages and is supported by an upward facing second receiving surface of the intermediate bracket and a stud is received in a slot extending from the upward facing receiving surface. Fasteners, such as wheel nuts, are threaded onto studs extending from the brackets to provide a structure or package suitable for shipping.

DESCRIPTION OF THE DRAWINGS

The following description and drawings set forth certain illustrative aspects and implementations for the subject matter of this application. These are indicative of but a few of the various ways in which one or more aspects and/or implementations may be employed. Further features of the subject matter of this application will become apparent from reading the description with reference to the accompanying drawings, in which:

FIG. 1 is an overall perspective view of a package of axle assemblies using a bracket system and method, according to aspects of this application;

FIG. 2 is an exploded perspective view of the package of axle assemblies and the bracket system illustrated in FIG. 1;

FIG. 3 is an enlarged elevational view of the package of axle assemblies and the bracket system illustrated in FIG. 1;

FIG. 4 is a perspective view of a portion the bracket system illustrated in FIGS. 1-3;

FIG. 5 is a front elevational view of a portion of the bracket system illustrated in FIG. 4;

FIG. 6 is a side elevational view of the bracket system illustrated in FIG. 5, taken approximately along line 6-6 of FIG. 5; and

FIG. 7 is a top plan view of the bracket system illustrated in FIG. 5, taken approximately along line 7-7 of FIG. 5.

DESCRIPTION

The subject matter of this application is described with reference to the drawings, in which like reference numerals are used to refer to like elements. In the description, for purposes of explanation, specific details are set forth in order to provide an understanding of the subject matter. It will be understood, however, that the subject matter may be practiced without these specific details.

A package 20 of four axle assemblies 22, according to an aspect of this application, is illustrated in FIGS. 1-3. The package 20 of four axle assemblies 22 is intended to be shipped by suitable transport means, such as a trailer pulled by a tractor. By way of example, a representative axle assembly 22 may be a TRLAXLE® trailer axle assembly available from Hendrickson Trailer Commercial Vehicle Systems in Canton, Ohio. A reusable bracket system 40 (best seen in FIGS. 4-5) forms the package 20 of four axle assemblies 22, as illustrated in FIGS. 1-3. The bracket system 40 receives and supports the axle assemblies 22 in a stacked and spaced arrangement suitable for handling and shipping.

The package 20 of four axle assemblies 22 is supported by the bracket system 40, constructed according to one aspect. Each of a pair of bracket systems 40 are used on respective opposite ends of the axle assemblies 22. The description for one side of the package 20 of axle assemblies 22 and the bracket system 40, such as that shown in FIG. 3, will also apply to the opposite side.

The lowermost pair of axle assemblies 22 in the package 20, as shown in the drawings, is supported on a pair of lower, bottom or base brackets 42 at opposite end portions of the axle assemblies. The base brackets 42 are intended to receive, support and secure the lowermost pair of axle assemblies 22 in a spaced relationship with one another and above or off of a support surface, such as a floor or a trailer bed. The base brackets receive and support a lower portion of each end of the respective axle assemblies 22. A pair of intermediate brackets 44 receives and engages an upper portion of each end of the respective axle assemblies 22. The uppermost pair or secondary level of axle assemblies 22 of the package 20 is supported from below and spaced from each other and the lowermost axle assemblies by the pair of intermediate brackets 44.

Each axle assembly 22 includes an axle 60 (FIGS. 1-2). Each axle assembly 22 also has a pair of wheel end assemblies 62 mounted at opposite end portions of the axle 60. Each wheel end assembly 62 includes a hub 64 with a plurality of studs 66 arranged in a circular array extending in an outward direction from the hub. Each hub 64 is shown with ten (10) interference fit studs 66 extending through the hub, but it will be apparent that any suitable number of studs may be employed. The hub 64 and studs 66 are intended to operatively mount a tire and wheel assembly (not shown) to the axle assembly 22, as is known. Suitable fasteners, such as wheel nuts 68 are provided to be threaded onto respective studs 66 to secure and clamp the axle assemblies 22 to the base bracket 42 and to the intermediate bracket 44 of the bracket system 40. This securement creates a structurally strong and stable package 20 suitable for shipping with the axle assemblies 22 securely stacked and spaced apart.

Each axle assembly 22 may include a pair of brake assemblies 70 mounted on opposite end portions of the axle 60 on respective wheel end assemblies 62. The brake assemblies 70 may be of any suitable brake system, for example a drum brake system or an air disc brake system, such as that shown. Components of the brake assemblies 70 can be damaged with improper handling, packaging and/or shipping.

The base bracket 42 of the bracket system 40 has a central or main body portion 80 (FIGS. 4-6) with a lower or bottom surface that provides contact with a supporting foundation, such as a floor or a bed of a truck or trailer. The base bracket 42 also may include a pair of opposite end portions 82 extending transversely from the main body portion 80. The end portions 82 are preferably formed integrally with the main body portion 80 by bending a cut steel plate. The base bracket 42 is preferably made from a suitable metal, such as ASTM Grade 50 steel plate about ⅜ inch thick. It is contemplated that other suitable metals could be employed, such as aluminum, or sufficiently strong plastics, such as fiber reinforced plastic.

The end portions 82 stabilize the base bracket 42 on a support surface, such as a floor or a bed of a truck or trailer. Each opposite end portion 82 extends transversely from the main body portion 80 at a suitable angle A as viewed in FIG. 7, such as about 15°. At least one of the end portions 82 extends a distance D (FIGS. 6-7) away from the main body portion 80 that is at least equal to, and preferably more than, a distance that the hub 64 and/or studs 66 extend from the main body portion when the package 20 is formed. This distance D that the end portions 82 extend from the main body portion 80 protects the hub 64 and studs 66 from damage by contact with a truck/trailer body, such as a sidewall extending upwardly from a bed, contact with structure or equipment that the package 20 would be moved past or contacted by unintentional material handling equipment, such as a forklift.

Each base bracket 42 has an upper receiving surface 100 (best seen in FIGS. 4-5) to engage and support a portion of one of the lowermost pair or at least a first one of the axle assemblies 22. While one receiving surface 100 will be described in detail, it will be apparent that the description equally applies to a base bracket 42 with more than one receiving surface that can receive, support and secure more than one axle assembly 22, such as the two receiving surfaces illustrated in FIGS. 4-5. The receiving surface 100 is preferably arcuate in shape that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface 100 is of a radius that closely matches the outer periphery of a portion of the wheel end assembly 62 of the axle assembly 22 that it supports.

The base bracket 42 also has a surface defining at least one scalloped slot 102 that extends from the receiving surface 100. The slot 102 may accept one of the studs 66. Preferably, multiple slots 102, such as the four shown in FIGS. 4-5, extend from each receiving surface 100. The slots 102 are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs 66 when an axle assembly 22 is lowered onto the receiving surface 100 of the base bracket 42. The arcuate end surface of each slot 102 is not necessarily intended to engage a stud 66 and support a portion of the weight of an axle assembly 22, because it is preferred that the receiving surface 100 performs this support and the loadbearing function. It will be appreciated that through holes or openings could be used in place of the slots 102 for receiving studs 66 and that this design choice would require additional maneuvering of the base bracket 42 and/or axle assembly 22 to place and properly support the axle assembly in the base bracket.

The base bracket 42 has a lower surface, as viewed in the drawings, on the main body portion 80 and in portions 82 that is adapted to rest on a support surface, such as a floor or bed or depth of a truck or trailer. The lower surface of the base bracket 42 may have a surface defining an elevated or relief portion 104 that serves to allow manual manipulation of the base bracket to move it or for access by material handling equipment, such as a forklift. The lower surface of the base bracket 42 may have more than one relief portion 104. The upper surface of the base bracket 42 also has an upper relief portion 106 that augments manual manipulation to move the base bracket or for access by material handling equipment.

When a wheel end assembly 62 of an axle assembly 22 is placed on a receiving surface 100 of the base bracket 42, at least one or more (four in the illustrated aspect) of the studs 66 may be received in respective slots 102 in the base bracket. Wheel nuts 68 are then threaded and tightened on the studs 66 against the outer surface of the base bracket 42 to clamp a portion of the hub 64 to the inner surface of the base bracket. Clamping the hubs 64 to the base bracket secures the axle assembly 22 to the base bracket 42 and minimizes or prevents relative movement in all directions. Clamping the hub 64 to the base bracket 42, thus, creates a structure that serves as a foundation for the package 20 that is strong, stable and suitable for shipping.

The base bracket 42 may accommodate a single axle assembly 22, but preferably a pair of axle assemblies are mounted on the base bracket. It will be apparent that a pair of base brackets 42 are used in the bracket system 40 at opposite ends of the axle assembly or assemblies 22. The base bracket 42 may include a cover material, such as plastic, rubber or the like, on at least one surface defining the receiving surface 100 and/or slots 102 and/or even the major side surfaces of the base bracket. This cover material can act as a cushion to prevent or minimize damaging the axle assemblies 22 from being scratched or other contact with the bracket system 40.

Straps or banding material may be used to connect at least a portion each of the brake assemblies 70 to one another, to one of the axles 60 or to the base bracket 42 to prevent or minimize relative rotation of the brake assemblies and potential damage during transit or handling. The base bracket 42 may include structure (not shown) that can be welded or otherwise attached to the base bracket to engage a portion of the brake assembly 70 and prevent or minimize relative rotation of the brake assembly. Optionally, the bracket system 40 may include a rod or “key” that can be inserted into a brake component of the brake assembly 70 to engage structure, such as the base bracket 42 or axle assembly 22, to prevent or minimize relative rotation of the brake assembly. Alternatively, the brake assembly 70 may be manipulated so at least one friction brake pad engages an associated rotor to prevent or minimize relative rotation of the brake assembly.

The bracket system 40 also includes the second, upper or intermediate bracket 44. The intermediate bracket 44 is preferably made from a suitable metal, such as ASTM Grade 50 steel plate about ⅜ inch thick. It is contemplated that other suitable metals could be employed, such as aluminum, or sufficiently strong plastics, such as fiber reinforced plastic. The intermediate bracket 44 has a lower end with a first receiving surface 120 (best seen in FIGS. 4-5). While one receiving surface 120 will be described in detail, it will be apparent that the description applies to an intermediate bracket 44 with more than one downward facing receiving surface that can receive, engage and secure a portion of more than one axle assembly 22, such as the two illustrated in FIGS. 4-5. The receiving surface 120 is preferably arcuate in shape of a radius that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface 120 is of a radius that closely matches the outer periphery of a portion of the wheel end assembly 62 of the axle assembly 22 that it supports.

The intermediate bracket 44 also has a surface defining at least one scalloped slot 122 that extends from the receiving surface 120. The slot 122 may accept one of the studs 66. Preferably, multiple slots 122, such as the four shown in FIGS. 4-5, extend from each receiving surface 120. The slots 122 are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs 66 when the receiving surface 120 of intermediate bracket 44 is placed on a wheel end assembly 62 of an axle assembly 22. The arcuate end surface of each slot 122 is not necessarily intended to engage a stud 66. It will be appreciated that through holes could be used in place of the slots 122 for receiving studs 66 that would also require additional maneuvering of the intermediate bracket 44 and/or axle assembly 22 to properly place the intermediate bracket on and receive the axle assembly.

The lower receiving surface 120 of the intermediate bracket 44 engages a portion of an axle assembly 22. At least one slot 122 extends from the first receiving surface 120 of the intermediate bracket 44 to accept a stud 66 of the lower axle assembly 22. Once the intermediate bracket 44 is placed on the axle assembly 22, at least one (four in the illustrated aspect) of the studs 66 is received in respective slots 122 in the intermediate bracket. Wheel nuts 68 are threaded and tightened on the studs 66 against the outer surface of the intermediate bracket 44 to clamp the hub 64 to the inner surface of the intermediate bracket. Clamping the hub 64 to the intermediate bracket secures the intermediate bracket 44 to the the axle assembly 22 and minimizes or prevents relative movement in all directions. Clamping the hubs 64 to the intermediate bracket 44 provides a strong, secure and solid structure that can receive at least one other axle assembly 22.

The intermediate bracket 44 may include a cover material, such as plastic, rubber or the like, on surfaces defining the receiving surface 120 and slots 122 to cushion and/or protect the hub 64 and studs 66. Such cover material can prevent or minimize damaging the axle assemblies 22 from being scratched or other contact with the bracket system 40.

The intermediate bracket 44 also has three second or upper receiving surfaces 140 (best seen in FIGS. 4-5) located at a second end of the intermediate bracket opposite from the lower receiving surfaces 120. While one receiving surface 140 will be described in detail, it will be apparent that the description applies to an intermediate bracket 44 with more than one upward facing receiving surface, such as the three illustrated in FIGS. 3-5, that can receive and support more than one axle assembly 22. The receiving surface 140 is preferably arcuate in shape of a radius that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface 140 is of a radius that closely matches the outer periphery of a portion of the wheel end assembly 62 of the axle assembly 22 that it supports.

One of the upper receiving surfaces 140 on the second end of the intermediate bracket 44 engages and supports a portion of at least one second or upper axle assembly 22 in a position above the lower axle assemblies. If a package 20 of four axle assemblies 22 is desired, the outermost pair of the three receiving surfaces 140 are used to receive and support the two axle assemblies. If a package 20 of five total axle assemblies 22 is desired, the central of the three receiving surfaces 140 is used to receive and support the third axle assembly in the secondary level of axle assemblies.

The intermediate bracket 44 has a surface defining at least one scalloped slot 142 that extends from the receiving surface 140. The slot 142 may accept one of the studs 66. Preferably, multiple slots 142, such as the four shown in FIGS. 4-5, extend from each receiving surface 140. The slots 142 are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs 66 when the receiving surface 140 of intermediate bracket 44 receives an axle assembly 22. The arcuate end surface of each slot 142 is not necessarily intended to engage a stud 66, because it is preferred that the receiving surface 140 performs this loadbearing support function. It will be appreciated that through holes could be used in place of the slots 142 for receiving studs 66 and that this would require additional maneuvering of the intermediate bracket 44 and/or axle assembly 22 to properly receive and support the axle assembly.

The intermediate bracket 44 may include a cover material, such as plastic, rubber or the like, on at least one surface defining the receiving surface 140 and slots 142 to cushion and/or protect the hub 64 and studs 66. Such cover material can prevent or minimize damaging the axle assemblies 22 from being scratched or other contact with the bracket system 40.

The intermediate bracket 44 may accommodate a single axle assembly 22, but preferably at least a pair of axle assemblies, mounted on the intermediate bracket. It will be apparent that a pair of intermediate brackets 44 are used in the bracket system 40 at opposite ends of each axle assembly 22.

Straps or banding material can be used to connect the brake assemblies 70 of the axle assemblies 22 to one another or to the intermediate bracket 44 to prevent rotation of the brake assemblies during transit or handling. The intermediate bracket 44 may include structure (not shown) that can be welded or otherwise attached to the base bracket to engage a portion of the brake assembly 70 and prevent or minimize relative rotation of the brake assembly. Optionally, the bracket system 40 may include a rod or “key” that can be inserted into a brake component of the brake assembly 70 to engage structure, such as intermediate bracket 44 or axle assembly 22, to prevent or minimize relative rotation of the brake assembly. Alternatively, the brake assembly 70 may be manipulated so at least one friction brake pad engages an associated rotor to prevent or minimize relative rotation of the brake assembly.

Once an axle assembly 22 is placed on a receiving surface 140 of the intermediate bracket 44, several studs 66 (four in the illustrated aspect) are received in respective slots 142 in the intermediate bracket. Wheel nuts 68 are threaded and tightened on the studs 66 against the outer surface of the intermediate bracket 44 to clamp a portion of the hub 64 to the inner surface of the intermediate bracket. Clamping the hub 64 to the intermediate bracket 44 secures the axle assembly 22 to the intermediate bracket and minimizes or prevents relative movement in all directions. Clamping the hubs 64 to the intermediate bracket 44 secures the axle assembly 22 to the intermediate bracket and creates a strong structure that creates the package 20 of three, four or five axle assemblies that is secure, stable and suitable for shipping. It should be apparent that one, two or three more axle assemblies 22 could be placed on the package 20 of four or five axle assemblies to create a package of five six, seven or eight axle assemblies by using another pair of intermediate brackets 44.

The base bracket 42 and intermediate bracket 44 are relatively easy to manufacture. For example, the base bracket 42 and intermediate bracket 44 can be formed from plate metal and cut to the desired shape by various cutting means, such as by laser, flame, plasma, or high-pressure fluid. The base bracket 42, once cut to a desired shape, can then have its end portions 82 bent to the desired angle A relative to the main body portion 80. The base bracket 42 and intermediate bracket 44 generally then do not require any further processing, other than maybe removing sharp corners that resulted from cutting and maybe painting and/or depositing cover material.

It has been found that by employing the reusable bracket system 40 constructed according to an aspect of this application, fifty-two axle assemblies 22 can be shipped on the same trailer load as previous shipping systems that were only able to accommodate twenty-six axle assemblies. This essentially doubles the number of axle assemblies that was previously carried on a trailer with wood pallets, wood blocks and steel bands. Further, the brackets 42 and 44 can be recovered, returned and reused, thereby eliminating the waste associated with the wood pallets, wood blocks and steel bands of the previous shipping systems. Thus, the bracket system 40 is economical, eco-friendly, easy to manufacture and lowers the possibility of damage.

Another aspect of this application is a method of building a package 20 of axle assemblies 22 in a stacked and spaced arrangement with the bracket system 40. The method includes the step of providing a pair of the base brackets 42 that are constructed as described above. The base brackets 42 are spaced apart with their end portions 82 facing in a direction opposite or away from one another. A first axle assembly 22 is placed on the pair of base brackets 42 so a portion of the hub of the first axle assembly engages the receiving surface 100 of the main body portion 80 of a respective one of the base brackets. Four studs 66 on each hub 64 are concurrently received in slots 102. Wheel nuts 68 are then threaded onto at least one, and preferably two or more, such as at least the laterally outermost studs 66 that are received in the slots 102. It will be appreciated that three or four wheel nuts 68 may be threaded onto respective studs 66 that are also received in the slots 102. The more of wheel nuts 68 being used will tend to provide a stronger clamping force and a more stable package 20.

The wheel nuts 68 are threaded and tightened to a desired torque against the outer surface of the base bracket 42 so a portion of the hub 64 is drawn against the inner surface of the base bracket. This clamps the hub 64, and thus one end of the axle assembly 22, to the inner surface of one of the base brackets 42. Clamping the hubs 64 to the base brackets 42 secures the axle assembly 22 to the base brackets and minimizes or prevents relative movement in all directions. Clamping the hubs 64 to the base brackets 42 provides a structure that serves as a foundation for the package 20 that is strong, sturdy, secure, stable and suitable for shipping.

This procedure may then be followed for another lower or first level axle assembly 22. The other axle assembly 22 is placed on the pair of base brackets 42 so a portion of the hub of the other first axle assembly engages another receiving surface 100 of the main body portion 80 of a respective one of the base brackets. Four studs 66 on each hub 64 are concurrently received in slots 102. Wheel nuts 68 are then tightened onto studs 66 to clamp portions of each hub 64 to a respective base bracket 42.

The method also includes providing a pair of intermediate brackets 44 that are constructed as described above. Each intermediate bracket 44 is placed on respective end portions of the pair of the lower or first level axle assemblies 22 from above so the portions of the axle assemblies engage a respective receiving surface 120 of the intermediate brackets. Four studs 66 on each end of the axle assemblies 22 are concurrently received in respective slots 122 of the intermediate bracket 44. Wheel nuts 68 are then threaded onto at least one, and preferably two, of the laterally outermost studs 66 that are received in the slots 102. Wheel nuts 68 are tightened against the outer surface of the intermediate bracket 44 so the hub is drawn against the inner surface of the intermediate bracket. It will be appreciated that three or four wheel nuts 68 may be threaded onto respective studs 66 that are also received in the slots 102. This clamps each of the hubs 64, and thus one end of the axle assemblies 22, to the respective inner surfaces of the intermediate bracket 44. Clamping the hubs 64 of the lower axle assemblies 22 to the intermediate brackets 44 secures the axle assemblies to the intermediate bracket and minimizes or prevents relative movement in all directions.

Then at least one other, upper or second level axle assembly 22 is placed on the intermediate brackets 44 so a hub 64 on each end portion of the second axle assembly engages and is supported by the second receiving surfaces 140 of the intermediate bracket. If only one second level axle assembly 22 is to be packaged and shipped, the center receiving surface 140 of the intermediate bracket is used. If two axle assemblies 22 are to be packaged, the two outer receiving surfaces 140 are used. If three axle assemblies 22 are to be packaged, then all three of the receiving surfaces 140 are used. Four other studs 66 on each hub 64 of the second axle assembly are received in respective slots 122 of the intermediate bracket 44. Wheel nuts 68 are threaded onto at least one, and preferably two, of the laterally outermost studs 66 of each hub 64 of the second level axle assemblies 22 that are received in the slots 102. It will be appreciated that three or four wheel nuts 68 may be threaded onto respective studs 66 that are also received in the slots 102.

Wheel nuts 68 are tightened against the outer surfaces of the intermediate brackets 44 so the hubs 64 are drawn against the inner surfaces of the intermediate brackets. This clamps the hubs 64, and thus both ends of the second level axle assembly 22 to the inner surface of the intermediate brackets 44. Clamping the hubs 64 to the intermediate brackets 44 secures the upper or second level axle assembly 22 to the intermediate brackets and minimizes or prevents relative movement in all directions. Clamping the hubs 64 to the intermediate brackets 44 provides the package 20 of at least three axle assemblies 22 that is stable and suitable for shipping without requiring steel band material to secure any of the axle assemblies to brackets 42, 44 of the package 20. If two or three additional upper or second level axle assemblies 22 are desired to be packaged and shipped in the bracket system 40, these same steps for each second level axle assembly are used to secure the additional axle assemblies to the intermediate bracket 44 in the appropriate other receiving surfaces 140.

It should be apparent that one, two or three more axle assemblies 22 could be placed on the package 20 of four or five axle assemblies to create a package of five six, seven or eight axle assemblies by using another pair of intermediate brackets 44 according to steps of this method. Accordingly, the improved bracket system 40 and method of shipping a package 20 of axle assemblies 22 are simple and effective and overcome disadvantages of operating previously known ways to ship.

The subject matter of this application has been described and illustrated with reference to at least one specific aspect. It is understood that the description and illustration are by way of example and not by way of limitation. From the above description and illustration, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications are intended to be covered by the subject matter of this application.

It is to be understood that the structure of the above-described bracket system may be altered or rearranged, or certain components modified, omitted or added, without affecting the overall concept or operation of the subject matter. For example, the location and arrangement of components may be adjusted based on specific design requirements. It is to be further understood that the subject matter of this application finds use in types of axle assemblies for heavy-duty vehicles, other than those shown and described herein, without affecting the concept or operation of the disclosed subject matter.

Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. Such terminology may include the words specifically mentioned, derivatives thereof, and words of similar import. Similarly, the terms “upper”, “lower”, “first”, “second” and other positional or numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context. 

What is claimed is:
 1. A system for packaging axle assemblies in a stacked and spaced arrangement, each axle assembly having a pair of wheel end assemblies mounted at opposite ends of an axle, each of the pair of wheel end assemblies including a hub with at least one stud extending from the hub, the system comprising: at least one base bracket including: a main body portion having at least one receiving surface for engaging and supporting a portion of a first axle assembly, the main body portion also having at least one surface defining a slot extending from a receiving surface for accepting a stud; and at least one end portion extends transversely from the main body portion; and at least one intermediate bracket including: at least one first receiving surface located at a first end of the intermediate bracket, the first receiving surface for receiving and engaging another portion of the first axle assembly to position the intermediate bracket relative to the first axle assembly; and at least one surface defining a slot extending from the first receiving surface for accepting another stud of the first axle assembly; at least one second receiving surface located at a second opposite end of the intermediate bracket, the second receiving surface for engaging and supporting a portion of a second axle assembly; and at least one surface defining a slot extending from the second receiving surface for accepting a stud of the second axle assembly.
 2. The system of claim 1 wherein at least one end portion extends transversely from the main body portion of the base bracket, the end portion extends a distance at least equal to a distance that the hub and studs extend from the main body portion.
 3. The system of claim 1 further including another receiving surface on the main body portion of the base bracket for receiving a portion of another axle assembly.
 4. The system of claim 3 further including another receiving surface on the intermediate bracket for receiving a portion of the other axle assembly.
 5. The system of claim 1 further including another base bracket for receiving and supporting a second end portion of the first axle assembly.
 6. The system of claim 5 further including another intermediate bracket for receiving and securing the second end portion of the first axle assembly.
 7. The system of claim 1 further including a cover material on at least one of the receiving surface and slot of at least one of the base bracket and intermediate bracket to protect components of the axle assembly.
 8. The system of claim 1 wherein the receiving surface has at least one arcuate surface.
 9. The system of claim 1 further including more than one surface defining a slot for accepting respective studs and that extends from the receiving surface of at least one of the base bracket and intermediate bracket.
 10. The system of claim 1 wherein a fastener is threaded onto the stud in the slot to secure an axle assembly to inhibit relative movement in all directions between a bracket and the axle assembly.
 11. The system of claim 1 further including structure for at least one brake assembly of the axle assembly to engage and inhibit rotation of the brake assembly.
 12. A bracket for supporting an axle assembly, the axle assembly having a pair of wheel end assemblies mounted at opposite ends of an axle, each wheel end assembly including a hub with at least one stud, the bracket comprising: a main body portion having at least one receiving surface for engaging and supporting a portion of an axle assembly, the main body portion also having at least one surface defining a slot extending from a receiving surface for accepting a stud; and at least one end portion extending transversely from the main body portion.
 13. A bracket for receiving a pair of axle assemblies, each of the pair of axle assemblies having a pair of wheel end assemblies mounted at opposite ends of an axle, each of the pair of wheel end assemblies includes a hub with at least one stud, the bracket comprising: at least one first receiving surface located at a first end of the bracket, the first receiving surface for receiving a portion of a first axle assembly, and at least one surface defining a slot extending from the first receiving surface for accepting a stud of the first axle assembly; and at least one second receiving surface located at a second opposite end of the bracket, the second receiving surface for engaging and securing a portion of a second axle assembly, and at least one surface defining a slot extending from the second receiving surface for accepting a stud of the second axle assembly.
 14. A method of packaging axle assemblies in a stacked and spaced arrangement, each axle assembly having a pair of wheel end assemblies mounted at opposite ends of an axle, each wheel end assembly including a hub with at least one stud, the method comprising the steps of: providing a base bracket having a main body portion with a receiving surface for engaging and supporting a portion of a first axle assembly, at least one surface defining a slot extending from the receiving surface for accepting a stud, and at least one end portion extending transversely from the main body portion; placing a first axle assembly in the base bracket so a portion of a first axle engages the receiving surface of the main body portion and a stud is located within the slot extending from the receiving surface; providing an intermediate bracket having a first receiving surface located at a first end of the intermediate bracket, the first receiving surface of the intermediate bracket for receiving and securing another portion of the first axle assembly and at least one surface defining a slot extending from the first receiving surface for accepting another stud of the first axle assembly, and the intermediate bracket having a second receiving surface located at a second opposite end of the intermediate bracket, the second receiving surface for engaging and supporting a portion of a second axle assembly and at least one surface defining a slot extending from the second receiving surface for accepting a stud of the second axle assembly; placing the intermediate bracket on the first axle assembly so the other portion of the first axle assembly engages the receiving surface of the intermediate bracket and a stud is located within the slot extending from the first receiving surface of the intermediate bracket; and then placing a second axle assembly in the intermediate bracket so a portion of the second axle assembly engages the second receiving surface of the intermediate bracket and a stud is located within the slot extending from the second receiving surface of the intermediate bracket.
 15. The method of claim 14 further including the step of clamping an axle to at least one of the brackets with a fastener threaded onto the stud located within the slot.
 16. The method of claim 14 further including the step of placing a pair of axle assemblies in respective receiving surfaces of the base bracket.
 17. The method of claim 16 further including the step of placing a pair of axle assemblies in respective receiving surfaces of the intermediate bracket. 